Removing And Installing Forks

Spring fork only can be removed and replaced, or complete fork assembly (spring and rigid fork)

can be removed and replaced as a unit.

Removing Spring Fork

1. Set motorcycle on rear stand.

2. Remove spring rod lock nuts (acorn-type).

3. Sit on front mudguard, or otherwise provide weight, to compress fork cushion (lower) springs. The spring rod larger nuts can then be easily removed, freeing upper recoil and upper bumper springs for removal.

4. Free lower end of horn assembly from horn bracket on mudguard.

5. If motorcycle is equipped with ride control, free the two eye bolts (10) and (12) Illus. 153, from spring fork crown; if equipped with shock absorber, remove the two bolts (T), Illus. 152.

6. If motorcycle is equipped with mudguard lamp, disconnect lamp wire from terminal on ignition-light switch and tie a piece of string approximately 30" long to wire terminal. Pull wire out of loom and untie or cut string, allowing it to extend through each end of loom. String will be used when reassembling to pull wire back through loom.

7. Raise front end of motorcycle high enough to permit removing front wheel and front mudguard—support motorcycle by means of suitable blocking underneath frame.

8. Remove front wheel. See "Removing Front Wheel,"

9. Remove brake assembly from left rocker plate, after disconnecting brake shackle from rigid fork.

10. Remove front mudguard, after removing nuts and locks from rocker plate rear studs, and the two bolts securing mudguard to rigid fork.

11. Remove rocker plate studs and rocker plates assembled.

12. Remove spring fork from motorcycle.

Installing Spring Fork

13. Place buffer springs and lower cushion springs on spring rods. Apply grease to rods. Pass rods up through spring rod bushings in rigid fork bracket. Bind lower end of spring fork to lower end of rigid fork with a strap or piece of heavy wire, to prevent forks from separating while compressing cushion springs.

Note: Before installing spring fork note type of rigid fork used. Earlier type rigid fork stem upper end and fork side upper ends were on same center line, whereas, center line of later type rigid fork stem upper end is %" to rear of fork side center line.

There are three different spring forks which can be used with rigid forks as follows:

Any spring fork used with an earlier type rigid fork can be installed with either side of fork crown facing rear.

If earlier type spring fork (fork crown not milled, approximately %" wide at center lower section) is to be used with later type rigid fork it will be necessary to remove sufficient metal from one side of fork crown lower center section to allow clearance for steering damper steel disc when fork is installed.

If later type spring fork (one side of fork crown milled) is to be used with later type rigid fork, install spring fork with milled side facing rear to allow clearance for steering damper steel disc.

If latest type spring fork (fork crown not milled approximately 5/8" wide at center lower section) is to be used with later type rigid fork, spring fork can be installed either way.

14. Insert two bolts in rigid fork bracket which mount the mudguard. Place a rod about 8" long and Vi" or larger diameter, on and across rigid fork brackets, resting it against the two bolts inserted in fork brackets. This rod will serve as a pry base for the leverage bar when compressing cushion springs. With a leverage bar about 18" long, anchored on top of the pry base rod and under the spring fork, lift upward to compress cushion springs sufficiently to install one of the rocker plates—then install the other rocker plate.

15. Install front mudguard.

16. Install front brake assembly on left rocker plate, and connect brake shackle to rigid fork.

17. Install front wheel.

18. Install upper bumper springs and upper recoil springs on the spring rods.

19. Remove blocking from underneath motorcycle frame.

20. Sit on mudguard to compress fork cushion (lower) springs. Tighten the two larger spring rod nuts sufficiently to provide 7/16" thread for the spring rod lock nuts (acorn-type). Install spring tod lock nuts and tighten.

21. If motorcycle is equipped with ride control, insert the two eye bolts (10) and (12) Illus. 153, through holes in spring fork crown; if equipped with shock absorber, insert the two bolts (T) Illus. 152, in spring fork crown. Install nuts and washers and tighten nuts securely.

22. Attach lower end of horn assembly to horn bracket on mudguard.

23. If motorcycle is equipped with mudguard lamp, tie string to wire terminal, pull wire through loom and connect wire to ignition-light switch terminal from which it was removed.

24. After assembly has been completed, check front wheel brake for correct adjustment.

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